Lecture 1_Chemical Industries

8/2/2019 Lecture 1_Chemical Industries

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Dr. Dhawal Shah

Lecture 1: Chemical Industries, itsLecture 1: Chemical Industries, itsLecture 1: Chemical Industries, itsLecture 1: Chemical Industries, its

structure, raw material, energystructure, raw material, energystructure, raw material, energystructure, raw material, energy

CHME 332 – Resource Engineering-I

Semester 2: 2011/12



Introduction

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Dr. Dhawal Shah

‘Instructor with Ph.D.’ @ METU NCC

Ph.D. from Singapore-MIT Alliance at National University of Singapore – July 2011.

Contact hours: drop an email to meet me anytime…anyplace.

[email protected]

Phone: 2992 (O); 0533 835 4412 (H)



Introduction

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The course is jointly taught by

Dr. Dhawal Shah (Course coordinator; 7 lectures)

Dr. Timur Dogu (3 lectures; [email protected])

Dr. Ufuk Bolukbasi (4 lectures; [email protected])

Assistant : Mr Saltuk ([email protected])

Midterm: 13 April

Tutorial: 20%; Midterm: 20%; Term-paper: 20%; final exam: 40% Course schedule is posted on METU ONLINE



Classroom policy

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You are free to move out of the class, if you feel so. But you should notdisturb others.

It’s going to be very difficult to earn two grades in my course: ‘AA’ and‘FF’…you will have to work hard to earn them.

Language…dialect…words…if not clear, you can stop me any time.

If you fail to submit the term paper on time or any of the assignments ontime: you are bound to fail.

No question is small…if you do not understand something..trust me..atleast half of the class does not.



Course Objectives

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Demonstrate the significance of natural resources (coal, oil, natural gas,biomass, water, air etc.) used in chemical process industries;

Discuss the effective use of natural resources and their sustainableconversion to useful products through chemical, biological and physicalprocesses;

Apply the general principles of equilibrium and rate concepts to chemicaland bio-processes;

Analyze waste minimization, environmental concerns and process

efficiency in selected case studies;

Realize the importance of green process engineering, environmentallyclean processes and products;



Chemical Engineering

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Chemical engineering: A branch of engineering which involves thedesign & operation of “large-scale” chemical plants, petroleum

refineries, and the like (Life sciences/pharma/micro-electronics).

Key: Process and (complex) system

In such industries, chemical engineers work in production, research,design, process and product development, marketing, data

processing, sales and throughout top management.



Chemical Industries

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Convert raw materials to useful products and improve the humanenvironment

Multi objective industries…examples

Multi Objective

Multi Functional

Multi ScaleEngineering Branch



Top chemical industries

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COMPANY,

HEADQUARTERS

2007 Chemical Sales,

billionsRank

BASF SE, Ludwigshafen,

Germany$65.3 1

Dow Chemical,Midland, Michigan,

United States

$53.5 2

INEOS, Lyndhurst, UK $43.6 3

LyondellBasell,

Houston, Texas, United

States

$42.8 4

Formosa Plastics, Taiwan $31.9 5

DuPont, Wilmington,

Delaware, United States$28.5 6

Saudi Basic Industries

Corporation, Riyadh,Saudi Arabia

$26.4 7

Bayer, AG, Leverkusen,

Germany$24.2 8

Mitsubishi Chemical,

Tokyo, Japan

$22.2 9



Commonly used raw materials

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water, air, salt, limestone, sulphur, coke and rock phosphate(abundantly available)

To produce primary or heavy chemicals such as mineral acids andalkalis which in turn is used

To produce secondary or intermediate chemicals like aniline, phenol

To produce more complex chemicals like drugs, dyes, explosives.



What do chemical engineers do: Multi

functional

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Design, development and operation of process plants

Research and development of novel products and processes

Management of technical operations and sales

In all these functions SUSTAINABILITY is important.



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Worldwide average profiles on sales

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Fine chemicals

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Multi-scale operations

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Atom-molecule state

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Rate of reactions

Mechanisms of reaction

Equilibrium of a reaction

Catalysis functioning

Photolithography (silicon industries)



Transport-in-bulk scale

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Gas Liquid (Mass Transfer)

Diffusion within the liquid

Liquid Solid (Mass Transfer) Mixing in the reactor (unit) (Hydrodynamics)

Heat transfer (Temperature distribution)



Plant scale

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Typical chemical process structure

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Physical Rate and Equilibrium Processes: Momentum, Heat, Mass

Transfer (Heat treatment, combustion, separation processes, fluid flow,

mixing etc.) Chemical Rate and Equilibrium Processes: Reaction Kinetics and

Thermodynamics



Factors that should be considered

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Which reactions are involved?

Thermodynamics of reactions,

Kinetics (rates) of reactions, use of catalysts. Operating parameter selection; T, P etc.

Mass transfer, heat transfer limitations.

Feed purification, separation processes. Product stream purification.

Economics of the process.

Process safety issues.

Environmental issues.

Process sustainability.



Birth of chemical engineering: Soap

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Soap making: Soda requirement

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1700’s the demand for soap increased requiring Na2CO3.

The alkali compounds, soda ash(Na2CO3) and potash(K2CO3), wereused in making glass, soap, and textile sand were therefore in greatdemand.

Alkali in the form of wood ashes (potash)and in the form of barilla(a plant containing 25% alkali), or from soda mined in Egypt, wereall very expensive.

Large natural soda reserves (trona) (Na2CO3-NaHCO3-2H2O) arealso available inTurkey (Beypazarı)



Birth of chemical industry

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Na2CO3 (Sodium carbonate)Other uses: Glass, water softner, production of dynamiteProblem: Natural resource

French Academy of Sciences (1783):“Make Na2CO3 from NaCl”Leblanc process (1791)2 NaCl + H2SO4 -> Na2SO4 + 2HCl (g) 800°CNa2SO4 + CaCO3 + 2 C -> Na2CO3 + 2CO2 + CaS

Problem: Pollution: HCl, CaS

British Alkali Act (1863): remove 95% of the HCl



Solvay Process

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Solvay process (1860) – process view

NaCl + CO2 + NH3 + H2O -> NaHCO3 + NH4Cl2 NaHCO3 -> Na2CO3 + H2O + CO2 heat >70 ºC

(CaCO3 -> CO2 + CaO)

2 NH4Cl + CaO -> 2 NH3 + CaCl2 + H2O-------------------------------------------------------------------------------2 NaCl + CaCO3 -> Na2CO3 + CaCl2 (overall reaction)

Think about process/systemRecycle everything: No more S, HCl



Birth of chemical industry

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Shifting of trends from

chemistry-oriented to

process-oriented.

Understanding and

design of different unit

operations like reactors,mixers, filteration,

sedimentation, etc.:

20th century



Birth of chemical engineering ing ing ing

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Lewis Norton

first course: Course X “Applied Chemistry”

First program at MIT 1888. “Chemical Engineering Program”

“General training in mechanical engineering and application of chemistry forthe manufacture of chemical products”

In 1891, the Department of Chemistry granted sevenBachelor's degrees for Chemical Engineering, thefirst of their kind to be bestowed anywhere. AfterNorton's death in 1893 at the age of 39, Professor

Frank H. Thorpe led Course X through a continuedrise in popularity. Thorpe's Outlines of IndustrialChemistry, which was published in 1898, isconsidered one of the first textbooks in chemicalengineering.

Lewis Norton



Ammonia synthesis

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Ammonia is one of the base chemicals used in the production of synthetic fertilizers etc.

About 175 000 000 tons of ammonia is produced per year, mostlyfor the production of fertilizers which are needed for theproduction of crops

About 1-2% of world energy consumption is due to ammoniasynthesis.



Ammonia production process

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N2 (g) + 3 H2 (g)⇌ 2 NH3 (g) (ΔH = −92.22 kJ·mol−1)

By far the major source of the hydrogen required for the Haber-Bosch process is methane from natural gas, obtained througha heterogeneous catalytic process

CH4 + H2O→

CO + 3 H2



Novel Catalysts May Save Considerable Energy

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Conventional Haber-Bosch process uses iron-oxide/alumina modified bypotassium.This catalyst shows activity atT = 400 – 500 oC

At this temperature p ≥ 100 atm is required due to chemical equilibriumlimitations.

AsT increases equilibrium conversion decreases (∆H<0; exothermic).

Operation at lower pressures (i.e., atmospheric pressure) requires

development of novel catalysts which will be active at much lowertemperatures .This will save significant energy.



First paradigm of chemical engineering

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First text book of chemical engineering



Second major introduction to ChemE

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Recent frontiers in chemical engineering

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Biotechnology, biomedical

Electronic materials

Advanced materials, polymers, composites

Energy, alternative fuels

Nanotechnology, nano-materials

Environmentally clean processes and products; safe processes, wastemanagement.

M j ibiliti f h i lM j ibiliti f h i lM j ibiliti f h i lM j ibiliti f h i l



Major responsibilities of chemicalMajor responsibilities of chemicalMajor responsibilities of chemicalMajor responsibilities of chemical

engineers in this ageengineers in this ageengineers in this ageengineers in this age

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Development of new processes which are safeand sustainable

Design and production of environmentally

benign and safe products.



Example of a benign process

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Refrigerators and air conditioners are extensively used today all overthe world. Can we do it with out them?



Refrigerant

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Before 1929, the common refrigerant were ammonia and methylchloride, which are highly toxic gas.

Until 1990 freons (CFC) were also very commonly used, whichcontributes to ozone depletion. They were phased out by MontrealProtocol.



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Ozone (O3) layer in the stratosphere absorbs some of the UV lightcoming from sun. Freons destroy O3



New refrigerants are being designed

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Example: R134: 1,1,1,2-Tetrafluoroethane CF3CH2F

Performance in the refrigerators is as good as conventional freons.

However, its ozone depletion capacity is zero.

It is less stable than conventional freons, so that it is decomposed beforereaching stratosphere

For the car air conditioner, we are still using CFC-12 and HFC-134a,which are both potent green house gas and ozone depleting substance.

On Mar 2, 2011, EPA has approved a new refrigerant HFO-1234yf, whichwill be used in car produced in 2013 (Announced by General Motors).



Green processes

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Fast depletion of natural resources and the resulting environmentalproblems opened a new and very important responsibility tochemical engineers to develop new environmentally clean and moreefficient processes and environmentally benign products.

Looking forward towards minimization of pollution.

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Lecture 1_Chemical Industries